Draft Final Report

PROMOTION OF RENEWABLE ENERGY, ENERGY EFFICIENCY AND GREENHOUSE GAS ABATEMENT (PREGA) Mongolia

ENERGY EFFICIENCY STUDY OF THERMAL POWER PLANT #4 ULAANBAATAR, MONGOLIA

A Technical Study Report1

February 2006

Prepared by the National Technical Experts: Mendbayar Badarch, Mongolian Nature and Environment Consortium (Environment Specialist), Damdinsuren Gantulga, IT Power Mongolia (Energy Specialist), Gombusoren Luvsan, MCS International Inc (Financial Analyst), and Jargal Dorjpurev, EEC Co. Ltd (Technical Specialist)

Table of Contents

List of Tables List of Figures 1.0 Background 1.1 1.2 1.3 1.4 1.5 2.0 3.0 Introduction Energy Sector of Mongolia Current Status of Power Plant TES#4 Upgrades/Renovations Environmental Protection

3 3 4 4 5 14 31 34 39 45

Energy Efficiency Improvement Options Conclusions

List of Tables Table 1.1.1 Table 1.2.1 Table 1.2.2 Table 1.2.3 Table 1.2.4 Table 1.2.5 Table 1.2.6 Table 1.2.7 Table 1.2.8 Table 1.3.1 Table 1.3.2 Table 1.3.3 Table 1.3.4 Table 1.3.5 Table 1.3.6 Table 1.3.7 Table 1.3.8. Table 1.3.9 Table 1.5.1 Table 1.5.2 Table 1.5.3 Table 1.5.4 Table 1.5.5 Table 1.5.6 Table 1.5.7 Table 1.5.8 Table 2.1 Table 2.1B Table 2.2 Avoided CO2 Emissions from the Energy Efficiency Options (TES#4) Mongolia: Energy Balances Existing Combined Heat and Power Plants in CES Boilers of the Existing CHPs in Mongolia Turbine Sets in Existing CHPs in Mongolia Power Plants of CES: Internal Use of Electricity, % CES: Electrical Efficiencies of the Power Plants Main Energy Indices of CES Operation GWH Specific Fuel Consumption and Calorific Values Present Status of Generators -Ulaanbaatar TES#4 Present Status of Steam Turbines Specifications of the Steam Turbines Rehabilitated and Rehabilitating Boilers Specifications of the Boiler Characteristics of the Boilers Present Status of the Components of Boilers Characteristics and Present Status of the Auxiliary Equipment Present Status of Electrical Equipment Temperature, Precipitation and Humidity in Ulaanbaatar City Method of Analysis Dust Data (Annual) SO2, NO2 and O2 Data Sound Level Measurement (Inside of Power Station) Sound Level Measurement (Outside of Power Station) Noise Standard Present Status of Environmental Equipment Measures that may improve the Efficiency of Coal-Fired Power Plants Avoided CO2 Emissions from Energy Efficiency Options Selected Clean Coal Technologies 5 7 8 9 10 10 11 11 13 16 17 17 18 19 22 23 23 25 34 35 36 36 38 38 38 39 40 41 41

List of Figures Figure 1.2.1 Figure 1.2.2 Figure 1.3.1 Figure 1.3.2 Figure 1.3.3 Figure 1.3.4 Figure 1.5.1 Figure 1.5.2 Figure 1.5.3 Development of GDP per Person and Electricity use per GDP Typical Load Curves of CES Grid General Layout of the TES#4 Coal Feed and Boiler Direct Firing Mill System Cool Handling System Ash Disposal Flow Diagram with Water Measuring Sound Level at Power Station Sound Level Measurement Points (Outside of Power Station) 6 12 15 21 22 30 37 37 38

1 1.1

Background Introduction

Today, global warming has become the subject of considerable public debate and the concern over the potential effect of CO2 emissions from fossil fuel power plants contribution to global warming, which is now a key issue for the future of power generation worldwide. Coal plays a key role in ensuring a sustainable future for Mongolia as this energy source is used for electricity and heat generation and the related CO2 accounts for around 90,0 % of total carbon emissions from Mongolia, therefore any strategy to reduce Mongolias CO2 emission levels must address the efficiency of coal based electricity and heat generation in the main cities and the province (aimag) centers. This paper addresses the assessment of energy efficiency options in the coal-fired power plant Thermal and Electric Station #4 (TES#4) in the context of sustainable development and greenhouse gas (GHG) mitigation strategies for Mongolian coal-fired power plants. The report is based on the characteristics of Mongolias largest coal-fired combined heat and power generation plant, TES #4. Although not specifically addressed, the importance of demand-side management, including energy conservation programs, as a common sense, cost-effective source reduction option cannot be overstated. Further, the current potential and future importance of renewable energy including solar-derived power should also not be underestimated. There is a wide range of electricity-generating technologies available that could significantly reduce GHG emissions worldwide. As stated in the Mongolian Energy Master Plan of 2001, the new heat and power generation capacities should be of new energy generation technologies, and should also include clean coal development technologies. Coal-fired power plants may vary greatly in their generating capacities and the types of boiler technology that they employ. As coal is the unique energy resource in Mongolia, we suggest to conduct a study which should demonstrate the commercial viability of new energy technologies with low greenhouse gas emissions in the near term future. Also it should focus on efficiency improvements and clean coal development technologies. Attention in this paper is focused on the coal-fired combined power and heat generation plants as they represent the largest use of coal in Mongolia. For Mongolia, more consideration has to be given to potential improvements in conventional coal-fired boiler steam turbine power plants, known as Rankine Cycles that are also capable of high efficiency and lower emission. In the world scale, much attention on searching for higher efficiency and lower emissions has been directed toward second-generation technologies2. In view of the possible near-term benefits, ADB has funded this energy efficiency technical study of UB thermal power plant #4. The purpose of this study is to establish, through engineering analysis, the most promising energy efficiency raising potentials available through improvements in the energy production cycles of the TES#4. Using the information on the measures that are taken to improve plant efficiencies in cases in the western countries, the potential options that could be implemented on the Mongolian brown coal-fired plant TES#4 are summarized in the Table 1.1.1. They have used the assumptions that electricity consumption, the total fuel heat rate and efficiency of the TES#4 are 2150 GWh, 7016,7 GWh and 30,64%, respectively, at the present level.
2 These technologies include coal gasification combined cycles, fuel cells that utilize hydrogen derived from coal gasification or natural gas fuel, and other advanced power plant systems that in addition to power generation may also generate chemical products.

Table 1.1.1 - Avoided CO2 Emissions from the Energy Efficiency Options (TES#4)
Reduction of Fuel heat rate GWh/yr CO2 emission reduction 103tons/yr CO2 emission reduction cost 103 US$/yr 835,21 1770,49 368,91 428,49 886,79
5

Action

1 2 3 4 5

Cooling tower film pack Coal drying with heat recovery On-line condenser cleaning system High efficiency turbine blades Extra air heater surface in the boiler + add. soot blowers

32,6 35,14 31,48 31,62 32,74

423,9 898,5 187,2 217,5 450,0

Avoided Coal Consumption 103tons/yr 104,40 221,31 46,11 53,56 110,85

Increased efficiency %

167,0 354,1 73,8 85,7 177,4

The above options are all taken to improve plant efficiencies in cases in the western countries and a soundly based engineering study with costs would need to be undertaken for a specific heat and power station such as TES#4 (see the above Table 1.1.1). Low rank coals in Mongolia have relatively high ash and moisture content. Coal cleaning has not been performed either at the mines or at the power plants. Coal mining and cleaning techniques can reduce the levels of trace elements that are contained in the ash after combustion and reduce coal transport costs. Presently, the permit system for sources of pollutants from power plants is not in force in Mongolia and the power plants are buying the relevant coal from the certain mines with designated coal, without considering moisture and ash contents, or coal washing or coal sizing or consistency issues either. The modernization concept of the performance of older steam turbines results in an increase in efficiency to a level comparable with that of new turbines, while maintaining the main dimensions and steam parameters of the existing turbines. The preferred solution is replacement of the components in the flow path including the inner casings with components of more advanced design for TES#4. This will offer the greatest potential for increasing turbine efficiency and output. New blading, modified seals and enlarged cross sections are the major issues (row 4 of the Table 1.1.1 shows estimates of the potential savings). 1.2 Energy Sector of Mongolia

As stated in the Mongolia: Sustainable Energy Sector Strategy (2002), the actions needed to improve energy efficiency and establish a legal framework for energy conservation include the creation of a legal environment for energy efficiency3 and improvements of efficiency in the thermal power plants and heat only boilers, including necessary rehabilitation work. Through improvements in energy efficiency, Mongolia can reduce its reliance on imported energy sources, reduce costs, mitigate the environmental impacts of energy use and increase its energy security. The use of energy efficient products and processes will
3

In this document it is stated that key actions needed are to develop, adopt and implement the energy efficiency law and a national program on energy efficiency.

yield additional benefits to Mongolias national energy production and delivery infrastructure by increasing productive activities. GDP and Energy Consumption. Figure 1.2.1 shows the trends in development of GDP and primary energy consumption in Mongolia. The specific GDP per head of population, in constant 1995 prices, has been continuously increasing, from 264'600 Tg in 2000, to 308'400 Tg in 2004, at an average rate of +3.55% p.a.. Total GDP, combining the population growth and the productivity growth (GDP per head of population), has grown from 2000 to 2004 by an average rate of 4.64 % p.a., from 632'521 million Tg in 2000 to 776'902 million Tg in 2004 (at constant 1995 prices).

Figure 1.2.1 - Development of GDP per Person and Electricity Use per GDP
GDP per Person; Electricity Use per GDP
6000

5000

4000

GDP 1'000 Tg. / 10 Persons

3000

2000

kWh / GDP mill. Tg.

1000

0 1990

1995

2000

2005

2010

2015

2020

GDP1'000Tg/10pop. "Optimistic" GDP1'000Tg/10pop. "Cautious"

GDP1'000Tg/10pop. "Medium" kWh / GDP mio Tg.

The relationship between real GDP and total energy requirements is best defined by energy intensities4. The less energy intensive the economy is, the more efficient it is. Therefore, energy efficiency improvement options are being developed that could be implemented in the generation, transmission, distribution and end use of electricity and heat. Energy Balance. As shown in Table 1.2.1 - Energy Balance, the energy intensive consumers, i.e. the main areas to focus energy efficiency product applications on in the present near term years, are in the industrial sector and communal and multifamily apartment buildings are the use of both electricity and heat and the energy efficiency improvements that are needed in the production of electricity and heat. Most of the main energy-using industries are located on industrial estates surrounding power stations in the main cities. Smaller industries located away from the main power stations have their own boilers but, in general, the use of combustion processes within a factory is rare. In 2003 just over 3137.7 million kWh (90%) of electricity were generated in Mongolia and a further 171.3 million kWh (10%) were imported. This electricity
4

Energy Intensity: The relationship between total energy requirements per real GDP. The lower the energy uses for the production of a unit of GDP, the less energy intensive the economy.

energy was used to cover the transmission and distribution losses and internal uses of the Energy Authority (33.5%), industry (42%), service and apartment buildings (16%) and agriculture and transport (4%). As for heat, in 2003, 2288,50 thousand Gcal of gross heat generation was consumed by industry (32%), 2777,20 thousand Gcal was used in commercial, service buildings and apartment buildings (39%), and 214.4 thousand Gcal was lost in heat transmission (3%). There is significant potential for energy savings through the use of energy conservation measures in the industrial sector, including the energy industries, and the service sector and residential buildings. These include the energy savings potential for motors, lighting, heating and ventilation systems and industrial processing, and improvements in the building fabric and services. Table 1.2.1 - Mongolia: Energy Balances ELECTRICITY BALANCE, GWh
Resources- Total Gross generation Import Distribution Consumption Of which: Industry & construction Transport & communication Agriculture Communal service buildings and apartment buildings Other Losses in transmission and distribution Station internal use Export

2000
3127,00 100,00% 2946,00 94,21% 181,00 5,79% 3127 1910 61,08% 100,00% 1182,00 61,88% 79,00 4,14% 21,00 1,10% 463,00 24,24% 165,00 8,64% 576,00 18,42% 616,00 19,70% 25,00 0,80%

2001
3213,00 100,00% 3017,00 93,90% 196,00 6,10% 3213 1948 60,63% 100,00% 1204,00 61,81% 87,00 4,47% 17,00 0,87% 476,00 24,44% 164,00 8,42% 603,00 18,77% 644,00 20,04% 18,00 0,56%

2002
3279,00 100,00% 3111,70 94,90% 167,30 5,10% 3279 2031,7 61,96% 100,00% 1260,10 62,02% 84,70 4,17% 22,00 1,08% 487,10 23,97% 177,80 8,75% 582,80 17,77% 649,00 19,79% 15,50 0,47%

2003
3309,00 100,00% 3137,70 94,82% 171,30 5,18% 3309 2194,6 66,32% 100,00% 1361,10 62,02% 91,50 4,17% 23,80 1,08% 526,10 23,97% 192,10 8,75% 489,20 14,78% 618,40 18,69% 6,70 0,20%

HEAT BALANCE, 1000 Gcal

Gross generation Station internal use Consumption-Total Of total consumption: Industry and construction Transport and communication

2000
6885,40 100,00% 138,00 2,00% 6747,40 98,00% 2620,10 38,83% 410,60

2001
6597,20 100,00% 59,60 0,90% 6537,60 99,10% 2343,70 35,85% 485,60

2002
6867,60 100,00% 144,90 2,11% 6722,70 97,89% 2428,50 36,12% 419,60

2003
7133,30 100,00% 335,50 4,70% 6797,80 95,30% 2288,50 33,67% 443,50

Agriculture Communal service buildings and apartment buildings Other Losses (T&D)

6,09% 33,30 0,49% 2655,10 39,35% 794,90 11,78% 233,40 3,46%

7,43% 36,50 0,56% 2990,50 45,74% 562,80 8,61% 118,50 1,81%

6,24% 36,20 0,54% 2843,10 42,29% 841,80 12,52% 153,50 2,28%

6,52% 40,50 0,60% 2777,20 40,85% 1033,70 15,21% 214,40 3,15%

Generation Mix in Mongolian Power Systems. Mongolias electricity supply system essentially consists of three separate, independent grids. In addition there are two-isolated aimag centres not yet connected to the three-grid system, each with a power plant supplying small local networks. Some 600-diesel units are used for off-grid rural soum (village) centre power supply. The largest of the three grids, which covers the area where most of the countrys population lives, is the Central Energy System or CES. The CES has presently a gross electricity demand of around 520 MW (including the Erdenet Copper Mine load and including power station internal usage), which accounts for approximately 95% of the total load in the country. The other two grids cover the western and eastern part of Mongolia and are very small in comparison with CES. The Western Energy System (WES) covers the aimags of Uvs, Bayan-Ulgiy and Khovd in the Altai Region with a total demand of about 8 MW and the Eastern Energy System (EES) serving the two eastern aimags of Dornod and Sukhbaatar with a total demand of about 11 MW. The main problems in the CES are (i) the largest generation unit at 100 MW provides about 20% percent of winter average load - its sudden stoppage leads to big power deficit; (ii) the power generating units have lower generator capacity and they lack automatic generation controls - they are not able to respond quickly enough to changes in load demands; (iii) self-generation or captive power and peaking capacity are virtually nonexistent; (iv) deficiencies are covered by selectively curtailing load on a rotating basis and/or by buying power and energy from Russia. For Mongolia, the most technically and financially viable solution in the near term is the energy conservation programs, including energy efficiency improvements in the power plants themselves. Central Energy System (CES) In the CES area the total installed capacity is 786.3 MW compared to a peak demand of about 475 MW. It is provided by the CHPs in Ulaanbaatar, Darkhan and Erdenet (Table 1.2.2). Table 1.2.2 - Existing Combined Heat and Power Plants in CES Power & Heating Plant Ulaanbaatar TES 2 Ulaanbaatar TES 3 Installed Capacity (MWe) 21.5 148.0 Available Capacity (MWe) 17.6 105.1 Capacity Boilers (MWth) 80 1448 District Heating (MWth) 43 562 Indus. Steam (MWth) 58 105 Commissioning Year 1961 1969 1968 1982

Ulaanbaatar TES 4 Darkhan Erdenet Total CES

540.0 48.0 28.8 786.3

432.0 38.6 21.0 614.3

2450 477 318 4773

918 210 140 1873

29 49 24 265

1983 1991 1966, 1986 1987 - 1989 -

All five old coal-fired power stations in the CES grid are of Russian design. They are cogeneration plants for production of base load electricity, hot water for district heating and process steam for industry. The CES is unable to meet the daily system demand with these plants due to their poor peaking capability. Outages reduce the actual power delivery by about 14-18 %. In addition, the CES uses 22% of the gross generation for its own use during the winter and this amount is very high. Most of the combined heat and power (CHP) plants operate with de-rated capacity due to the fact that the coal quality is much below that of the design coal for these boilers. The situation is aggravated by coal supply and spares parts problems. A serious aspect of the system is its age. The remaining lifetime of the power plants is only 12 years on average with the Ulaanbaatar Power Plant No. 4 (TES 4) capable of operating possibly for 15 years more. It is apparent to professional circles that major refurbishment must be considered in the short-term and medium term replacement of the generating capacity has to be planned for soon. Rehabilitation projects on the CHPs TES 3, TES 4 in Ulaanbaatar, the Darkhan CHP and the Choibalsan have been carried out and are partly financed by loans from various donors. A major part of these rehabilitation projects was devoted to boiler refurbishment, which improved considerably the reliability of operation. A new rehabilitation project is ongoing on TES 4 with a 50 million US$ loan from Japan. Table 1.2.3 - Boilers of the Existing CHPs in Mongolia CHP Boiler Type Capacity t/h Steam 420 420 220 220 75 75 35 35 75 Number of boilers 4 4 4 3 5 1 1 1 2 Boilers Rehabilitation Year 1997-1999 2002-2006 1996-2000 1/1999-2001 1 / 2001 -

UB TES 4 UB TES 4 UB TES 3 UB TES 3 UB TES 3 UB TES 3 UB TES 2 UB TES 2 UB TES 2

Single drum, pressurised circulation, direct firing system Single drum, pressurised circulation, Indirect firing system Single drum, natural circulation, direct firing system Single drum, natural circulation, Indirect firing system Single drum, natural circulation, direct firing system Fluidised bed combustion Fluidised bed combustion With chain grate Single drum, natural circulation, direct firing system

Darkhan Erdenet

Single drum, natural circulation, indirect firing system Single drum, natural circulation, indirect firing system

75 75

9 6

3 / 1995-1997

Table 1.2.3 above presents an inventory of all CHP boilers in the CES. It gives their main features and their steam output. It also shows those that have been rehabilitated. Table 1.2.4 presents an inventory of all CHP turbines in the country. It shows their main features, their power generating capacity and if they have been rehabilitated. Table 1.2.4 - Turbine Sets in Existing CHPs in Mongolia CHP UB TES 4 UB TES 4 UB TES 3 UB TES 3 UB TES 2 Erdenet Turbine Type With extraction for district heating With extraction for process steam and district heating With extraction for process steam and district heating With extraction for process steam and district heating With extraction for process steam and district heating Back pressure With extraction for process steam and district heating Back pressure With extraction for process steam and district heating Capacity MWe 100 80 25 12 12 6 3.5 12 8.4 12 Number of Turbines 3 3 4 4 1 1 1 1 2 4 Turbine Rehabilitated Year 3 2001 - 2006 2 1998 1 1997

Darkhan

The in-station auxiliary power and heat consumption are very high in the existing CHPs and amounts on average to about 19% of the gross generated electricity and to about 10% of the gross generated heat (Table 1.2.5). These figures are very high compared to international standards and add to the extremely low plant efficiencies for power generation and overall fuel utilisation values when considering cogeneration. Net electricity export compared with the gross generation is on average for all stations only 78%, or self-use of 22%. A normal expected value for self-use is in the range of 10-12% for a coal-fired CHP operation. Table 1.2.5 - Power Plants of CES: Internal Use of Electricity, % 1997 17.79 31.62 20.25 19.55 1998 18.54 31.62 19.91 19.55 1999 17.89 28.15 19.48 20.22 2000 19.56 27.83 20.11 19.06 2001 18.68 25.60 20.71 17.67 2002 18.34 25.40 19.89 17.75 2003 18.22 24.6 18.27 18.78 2004 17.76 25.57 17.17 18.79 (2005) 17.76 24.0 16.6 17.8

TES#2 TES#3 TES#4 Darkhan TES

10

ERDENET TES
CES

28.04
22.00

28.30
22.00

27.33
21.00

25.38
22.00

25.62
22.00

25.84
21.00

25.86
19.78

23.82
19.08

23.8
18.3

The fuel utilization efficiency, defined as net energy (electricity and heat) export compared to total fuel heat (LHV) input to the boiler is in the range of 40-70% for all stations, with the average in the magnitude of only 55% [Energy master plan, 2001]. In a modern CHP scheme figures of 70-90% are achievable. Reasons for the low total heat utilization are: low boiler efficiencies; low steam/water cycle efficiencies; excessive own consumption of heat and power; low condensate return and high-energy (radiation, leakage, etc) losses. Loss of condensate is in the range of 10-30%, with the average in the magnitude of 15%. Since makeup water is scarce, this is contributing negatively to the operation cost of the stations. The circulating water temperatures of the district heating systems are typically in the magnitude of 85 (supply) to 55 (return) C. Commonly supply temperature is expected between 110-140 C and return temperatures between 70-90 C [Energy Master Plan, 2001]. The electrical efficiencies of the all power plants in the CES grid are given in the Table 1.2.6. Table 1.2.6 - CES: Electrical Efficiencies of the Power Plants 1997 TES#2 TES#3 TES#4 Darkhan TES ERDENET TES CES 28.4 20.4 29.7 28.0 29.1 14.9 1998 28.0 21.7 30.4 26.3 32.1 14.7 1999 32.6 23.9 31.0 29.3 29.5 14.5 2000 28.4 27.7 31.6 27.2 32.5 14.6 2001 28.9 26.8 32.3 29.5 32.9 16.3 2002 28.9 25.6 31.6 29.4 33.2 16.3 2003 29.0 28.1 33.9 29.5 33.1 15.5 2004 29.1 28.2 34.3 29.6 33.9 17.7

Energy Generation in CES. Generation, peak loads and export and import of electricity for the CES grid are given in Table 1.2.7. From this table, the largest power plant is the combined heat and power plant (TES#4) and it produces 56.6 % of total gross generation of the power system. Table 1.2.7 - Main Energy Indices of CES Operation, GWh 1999
TES#2 (CHP) TES#3 (CHP) TES#4 (CHP) Darkhan TES (CHP) Erdenet TES (CHP) Total gross generation Import Export Total demand Peak load, MW Total demand, GWh 94,3 515,9 1825,3 196,1 108,6 2740,2 194,8 24,9 2910,1 499 2910,1

2000
94,2 529,4 1909,6 199,9 112,7 2845,8 151 24,9 2971,9 526 2971,9

2001
86,6 530,7 1958,1 205,8 116,7 2897,9 156,8 17,8 3036,9 538 3036,9

2002
105,6 543,8 2001,7 223,8 128,6 3003,5 116,3 8,1 3111,7 532 3111,7

2003
107,2 550,0 2009,2 229,4 131,9 3027,7 131,1 6,7 3152,1 539 3152,1

2004
105,6 565 2150 238,9 135,5 3195,0

3198,4 545 3198,4

11

Typical daily load curves of the CES and its power plants are given in the Figure 1.2.2. From the load curves, it can be seen that TES #4 covers 54-66 % of the total demands in the CES grid. Figure 1.2.2 - Typical Load Curves of CES Grid
Typical Daily Load Curve, Jan
600 500 400 MW 300 200 100 0 1 3 5 7 9 11 13 15 17 19 21 hour 23 import /export/-/ PP#4 ErdPP DarPP PP#3 PP#2

Typical Daily Load Curves, April

500 400 MW 300 200 100 0 1 3 5 7 9 11 13 15 17 19 21 hour 23 Import /export/-/ PP#4 ErdPP DarPP PP#3 PP#2 1 3 5 7 9 11 13 15 17 19 21 23 import /export/-/ PP#4 ErdPP DarPP PP#3 PP#2

Typical Daily Load Curve, Jul

400 350 300 250 200 150 100 50 0 hour

MW

12

Typical Daily Load Curves, Sep

500 400 MW 300 200 100 0 1 3 5 7 9 11 13 15 17 19 21 hour 23 Import /export/-/ PP#4 ErdPP DarPP PP#3 PP#2

Typical Daily Load Curves, Dec

600 500 400 MW 300 200 100 0 1 3 5 7 9 11 13 15 17 19 21 hour 23 Import /export/-/ PP#4 ErdPP DarPP PP#3 PP#2

The specific fuel consumption and coal calorific values are given in the Table 1.2.8. Table 1.2.8 - Specific Fuel Consumption and Calorific Values
2000 year fuel specific calorifi consumption c value for for heat QHPelectrical kg/Gcal kcal/kg
g/kWh

2001 year fuel specific calorific consumption value for for heat QHPelectrical kg/Gcal kcal/kg
g/kWh

2002 year fuel specific calorifi consumption c value for for heat QHPelectrical kg/Gcal kcal/kg
g/kWh

TES#2 TES #3 LP TES #3 HP TES #4 Darkhan TES Erdenet TES SYSTEM

574,26 184,84 515,3 197,6 475 196,4 388,93 184,12 451,9 168,8 340,79 414,3 185,4

3274 3265 3265,0 3360,1 3544,8 3371,8

597,22 472,7 463,5 388,02 416,54 408,57

187,6 192,1 192,9 183,78 173,36

3313 3406,1 3406,1 3240,8 3826,2 3364,8

643,53 184,28 448,0 198,8 489,5 195,2 389,33 184,09 418,46 187,27 413,49 185,65

3409,5 3275,7 3275,7 3216,7 3733,0 3314,6

13

2003 year 2004 year fuel specific calorific fuel specific calorific consumption value consumption value for for heat QHPfor for heat QHPelectrical kg/Gcal kcal/kg electrical kg/Gcal kcal/kg
g/kWh g/kWh

2005 year fuel specific calorific consumption value for for heat QHPelectrical kg/Gcal kcal/kg
g/kWh

TES#2 TES #3 LP TES #3 HP TES #4 Darkhan TES Erdenet TES SYSTEM

649,34 184,11 190,5 460,1 191,1 364,59 182,48 416,49 187,59 343,12 395,49 184,79

3225,4 3432,8 3432,8 3251,4 3836

638,85 539,29 424,47 355,92 392,45

189,78 207,70 192,50 180,3 185,61

2938,0 3378,0 3378,0 3161,0 4036,1

3370,8

388,00

164,07

1.3 Current Status of Power Plant TES#4 Overview. The combined heat and power plant #4 (TES#4) was constructed under the design of the former USSR's equipment suppliers. The plant consists of 74 buildings and facilities located 3-20 km from the plant and includes an ash pond, water supply pump station, service building, administration building, laboratory and test center etc. occupying 12.8 hectares (Figure 1.3.1). The station employs about 1400 people. Thermal Power Plant #4 in Ulaanbaatar consists of 3x100 MW steam turbine generator units (#2, #3 and #4) and 3x80 MW steam turbine generator units (#1, #5 and #6). The steam turbine generator units are connected to eight (8) boilers through a common main steam header. The first steam turbine generator unit was commissioned in 1983 and the last unit in 1991. The current combined maximum continuous rating of all the eight steam turbine generator units is 540 MW. The gross energy generated in 2004 was 2150,0 GWh, out of which, about 17,7% was used internally for auxiliary equipment power consumption. The station supplies power to the CES grid at 220 kV and 110 kV as well as providing hot water to the city's space heating system when needed during the heating season (September 15 to May 15) and steam to adjoining industries. The UB TES #4, which is the major power station of the country, has been partly rehabilitated under a Japanese soft loan from 1998-2006. In Phase 1 of the project, boiler units #1, #2, #3 and #4 have been rehabilitated, and new coal mills and new control systems installed. This has resulted in remarkable improvements especially in terms of reduction in fuel consumption together with emission control. The project also significantly contributes to atmospheric pollution control. The emission control of CO2 is one of the most urgent global issues and will be regulated more strictly in Mongolia in the future. To cope with this urgent need, the lasting contribution of the project to the emission control is indispensable.

14

Figure 1.3.1 - General Layout of the TES#4

15

The components of the rehabilitation project of the 4th Thermal Power Plant in Ulaanbaatar, Phase II5, sponsored by Japan Bank for International Cooperation (Loan agreement MON-P6, March 26, 2001), are (i) Conversion to direct firing system for boiler #5 through #8, (ii) Rehabilitation of controls and instrumentation for boiler #5 through #8, (iii) Replacement of boiler tubes (super-heater, economizer, etc), (iv) Replacement of excitation equipment for power generator (#1 through #4). It is expected that the planned measures will increase the available capacity of the plant by about 46 MW. Furthermore it can be assumed that the plant will not need to be retired before 2020, if a thorough maintenance and overhaul program is carried through after rehabilitation. A certain de-rating, however, will have to be considered for the last years of the forecasting period. Steam Turbine Generator Units. There are 4 generators - 2x80 MW & 2x100 MW @ 10.5 kV stepping up voltage through 4x125 MVA, 10.4 kV/242 kV + 2x2.5% unit transformer, and 2 generators 1x80 MW & 1x100 MW @ 10.8 kV stepping up voltage through 2x125 MVA, 10.5 kV/121 kV + 2x2.5% unit transformers (Table 1.3.1-1.3.3). Table 1.3.1 - Present Status of Generators Ulaanbaatar TES#4 Commissioning year
83.10.12 84.11.26 85.12.27

Type
1 2 3 4 5 6 TVF-1202U3 TVF-1202U3 TVF-1202U3 TVF-1202U3 TVF-1102U3 TVF-1102U3

Year of last major overhaul

2000-11 2000-10 1995-06 1998-06

Capacity
80 100 100 100 80 80

Present Status
Generator: Minor troubles such as burnout of metal, leakage of oil have occurred. Regular checking is required. Exciter: The exciting systems have been replaced by the Japanese loan project.

83.11.18

1996-03 1999-01

The first steam turbine generator Unit #1 of 80 MW and Units #2, #3 and #4 of 3x100 MW nominal power output were commissioned during 1983-86 and the last 2x80 MW (Units #5 and #6) were commissioned during 1990-91, all with Russian support. The current maximum continuous rating of each of these steam turbine generator units is 80 MW and 100 MW, as applicable. The normal loading/ unloading ramp rates are 15 MW/min for 80 MW units and 10 MW/min for 100 MW units. The emergency loading/ unloading ramp rates are 20 WM/min for all the units.

Contract amount 6139,0 million Yen, 0,75%p.a, 40 years w/grace period of 10 years from JBIC

16

Table 1.3.2 - Present Status of Steam Turbines Year of last major overhaul
2000,06 2000,05 1995,06 1998,06 1996,03 1999,01

Type
PT-80130 T-100130 T-100130 T-100130 PT-80130 PT-80130

Commissioning year

Capacity

Present Status

1 2 3 4 5 6

1983,1 1984,11 1985,12 1986,12 1990,02 1991,12

80MW 100MW 100MW 100MW 80MW 80MW There are no specific problems and renovation is not necessary for the casing, rotor, bearing pedestal, nozzle, governor and emergency governor. Periodical inspection only needed.

Two major equipment failure incidents regarding the steam turbine generator units were reported in the past: Unit #1 shaft was broken, and Unit #5 shaft became warped in service. In both cases the parts were shipped to the Original Equipment Manufacturer in Russia for repair. The cause of these failures was not disclosed. Table 1.3.3 - Specifications of the Steam Turbines Manufacturer
Type of steam turbine (Non-reheat, condensing) Live Steam Nominal Output condition Rated Output Maximum Output Steam Pressure Steam Temperature Live steam flow Turbine Exhaust Flow Pressure Cooling water temp. /rated flow Rotation speed Process steam Max. flow Rated flow Rated pressure Rated pressure in Upper district heating steam heating extraction point Lower district heating Load on district Rated/Max heating extraction point Feed water system

USSR Energomach Export

Tandem close coupled

USSR
Triple tandem compound

80 MW 100 MW 80 MW 110 MW 100 MW 120 MW 130 kgf/sq.cm(12.7 Mpa)(before stop valve) 555 deg.C (before stop valve) Max. 470 t/h Max. 485 t/h, Rated 480 t/h Max. 220 t/h Max. 325 t/h Design 0.057 kgf/cub.cm (0.0056 Mpa) 20deg.C/8,OOOcub.m/h 20deg.C/16,000cub.m/h 3,000 rpm 3,000 rpm 300 t/h 185 t/h 13.0 kgf/cub.m (1.275 Mpa) 1.0 kgf/sq.cm 0.6-2.5 kgf/sq.cm 0.35 kgf/sq.cm 69/104 Gcal/h 0.5-2.0 kgf/sq.cm 175/184 Gcal/h

249 deg.C 4LP+D+3HP

232 deg.C 4LP+D+3HP

17

The control panels of the steam turbine generator Units #1-3 are installed in one control room shared with boilers #1-4 controls and the control panels of the steam turbine generator Units #4-6 are installed in another control room shared with boilers 5-8 controls. Most of the steam turbine generator units' controls are original, and some of the controls have been partially refurbished. Boilers. There are eight (8) boilers (Russian made, BKZ-420-130-10C type), each with a capacity of 420-t/h steam (140 kg/cm2, 560C) output, the first six boilers were commissioned during 1983-87 along with the first four steam turbine generator units and the last two boilers were commissioned during 1990-91 along with the last two steam turbine generator units (Table 1.3.4 and 1.3.6). Table 1.3.4 - Rehabilitated and Rehabilitating Boilers Com missi oned year
1983,1 1984 1984,1 1985,1 1986,1 1987,1 1990 1991,1

Type
1 2 3 4 5 6 7 8 BKZ-420-140 BKZ-420-140 BKZ-420-140 BKZ-420-140 BKZ-420-140 BKZ-420-140 BKZ-420-140 BKZ-420-140

Design Capaci ty
420 420 420 420 420 420 420 420

Type of firing system

Direct firing Direct firing Direct firing Direct firing Indirect firing Indirect firing Indirect firing Indirect firing

Design coal
Baganuur Baganuur Baganuur Baganuur Baganuur Baganuur Baganuur Baganuur

Rehabilitated by the Japanese Financing

Phase I Phase I Phase I Phase I Phase II Phase II Phase II Phase II 1999 1999 1998 1999 2004-2006 2004-2006 2004-2006 2004-2006

Usually four boilers are in service with one of them as hot standby. During peak load, five boilers could be in service. The original boiler design incorporates corner fired (4x3 burners) units, with direct fired Boilers #1-4 serviced by four (4) vertical bowl mills each, and indirect fired Boilers #5-8 serviced by two horizontal ball mills each. All indirect fired boilers are being converted to direct firing, which will be completed by 2005. The coal to the power plant6 is the B2 type supplied from Baganuur and Shivee Ovoo coal (3100-3500 kcal) mines. This coal has less than 0.6% sulphur. In addition, M-40 type heavy oil fuel at a consumption (for each steam generator) of 75-80 tons heavy fuel per hour and 25 tons per hour of light oil are used in the starting period of the boilers from the cold reserve. Coal and oil reserves are maintained with open-air coal storage yard of 240000 tons, heavy oil tank of 5000 cubic meters, and light oil tank of 700 cubic meters. Electrostatic precipitators (ESPS) are provided for removing the fly ash in the flue gases from the boilers. The upgrade of the original Boilers #1-4 controls to DCS control was completed in 2003. The upgrade of Boiler #5-8 is currently in progress and will be completed by 2006.
6 Per hour: The TES#4 consumes 282 tons of coal, 1531 tons of water and generates 242 MW electricity and 249,4 Gcal heat (239,7 Gcal in water and 9,4 Gcal in steam), while consuming 75 tons of Shiyee-Ovoo and 66 tons of Baganuur coal per hour.

18

Table 1.3.5 - Specifications of the Boiler

Manufacturer Type Unit No. Boiler Steam Condition USSR Indoor, radiant, single drum, natural circulation type Unit 1 to 8 420 t/h (Superheater Outlet) 140 kgf/cm2 (14Mpa) (Superheater Outlet) 560 deg.C (Superheater Outlet) Mongolian Coal (Baganuur, Shivee-ovoo) 4,000 kcal/kg (956 kJ/kg)-3,000 kcal/kg Pendant Type Single Furnace, Water Wall Tubular Type Corner Firing (4x3 stages) Electrostatic Type Slurry Ash with water circulation system Horizontal tube mill with flue gas drying system (2) Semi-direct storage bin (Blowing by primary fan) Balanced Draft

Boiler Capacity Steam Pressure Steam Temperature Fuel Used Description High Calorific Value Type Super heater Boiler Furnace Air Heater Coal Burner (Numbers) ESP Ash Treatment System Coal Pulverizer (Numbers) Pulverized Coal Firing System Ventilation System

(Note) Coal pulverizing and pulverized coal firing systems for the Boiler Nos.1 to 4 are now under refurbishment to a direct firing system.

19

Figure

1.3.2 - Coal Feed and Boiler

20

Figure 1.3.3 - Direct Firing Mill System

21

Table 1.3.6 - Characteristics of the Boilers Description

Steam Pressure of drum Temperature after super heater primary stage Temperature after super heater secondary stage Pressure after super heater secondary stage Flow Feed water Temperature inlet ECO1 Temperature outlet ECO1 Temperature inlet ECO2 Temperature outlet ECO2 Pressure Flow Flue gas Temperature inside Temperature outlet stage Temperature outlet secondary stage Temperature outlet stage Temperature outlet secondary stage Temperature outlet stage Temperature outlet stage Furnace Super heater primary Super heater Air Heater secondary Economizer Air Heater primary Economizer primary

Unit
ata
0

Design
160 393 452

Max
160 420 460

Operational
160 393 452 145 420

C C

ata t/h
0 0 0 0

C C C

230 245 249 270 220

346 346 349 349 167

C ata t/h
0

C C C C C C C C -

1603 521 827 669 755 180 310 132

1604 560 929 730 838 191 417 141

1603 521 827 669 755 180 312 132 75-85 tonne R90-30-35%

0 0

Temperature outlet Coal Consumption Capacity of coal pulverisation Flue gas analyzator O2 CO

t/h mm2

35% 4-6% 20mg/m

3

4-6% 20mg/m
3

4-6% 20mg/m3

22

The present status of the main components of all boilers is given in Table 1.3.7. Table 1.3.7 - Present Status of the Components of Boilers Existing conditions with recent rehabilitation.
Drum Water Drum Furnace Super Heater Re-heater Economizer Valves Pumps FDF GRF IDF PGF Burner In good condition and renovation is not necessary. Non-existence of the Water Drum (Existing only tube header) Tubes were replaced in Japanese loan project. Header is in good condition. Header is in good condition. Tubes were replaced in Japanese loan project. Non-existence of Re-heater. Header is good condition. Tubes (#6,7) were replaced in Japanese loan project. Safety, steam and feed water valves are in good condition. Feed water circulating and boiler feed pumps are good condition. To be renovated by the Plants own finance. To replace the fan by the plants own finance. To be renovated by the plants own finance. Replaced by the Japanese loan project (boilers #5,6,7,8). Replaced by the Japanese loan project (boilers #5,6,7,8).

The specifications and present status of the auxiliary equipment of the boilers are given in the Table 1.3.8. Table 1.3.8 - Characteristics and Present Status of the Auxiliary Equipment Ulaanbaatar - TES#4: Auxiliary Equipment 1 No of boiler
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Indiced draft fan

Year of commissi oning

1983 1984 1984 1985 1986 1987 1990 1991 1983 1984 1984 1985 1986 1987 1990 1991

Type
DOD31.5 DOD31.5 DOD31.5 DOD31.5 DOD31.5 DOD31.5 DOD31.5 DOD31.5 VDN-32B VDN-32B VDN-32B VDN-32B VDN-32B VDN-32B VDN-32B VDN-32B

Capacity
934*103 934*103 934*103 934*103 934*103 934*103 934*103 934*103 490*103 490*103 490*103 490*103 490*103 490*103 490*103 490*103

Capacity of motor
200 1998 2000 1998 1999

Present status
Good Good Middle Middle Good Good Good Good Good Middle Middle Middle Good Good Middle Middle

Forced draft fan

23

Ulaanbaatar - TES#4: Auxiliary Equipment 2 Year of commissioni ng

1983 1984 1984 1985 1986 1987 1989 1991

No of boiler
1 Ash handling system 2 3 4 5 6 7 8

Type

Capacity

Year of last major overhaul

1998 -

Present state of operation

Middle Middle Middle Good Good Good Bad Good

EGA2 EGA2 EGA2 EGA2 EGA2 EGA2 EGA2 EGA2

10.5 t/h 10.5 t/h 10.5 t/h 10.5 t/h 10.5 t/h 10.5 t/h 10.5 t/h 10.5 t/h

Ulaanbaatar - TES#4: Auxiliary Equipment 3 Year of commissi oning

1999 1999 1998 1999 1985 1986 1990 1991 1999 1999 1998 1999 1985 1986 1990 1991

Equipment

Boiler

Type

Capacity

Last major overhaul year

2000 1998

Present status
Normal Normal Middle Middle Good Middle Bad

1 Roller mill 2 3 4 Ball mill ShBM-320/675 ShBM-320/675 ShBM-320/675 Exhaust fan 5 6 7 8 1 2 3 4 MV-20A MV-20A MV-20A MV-20A 5 6 7 8

SM-19 SM-19 SM-19 SM-19 SHBM SHBM SHBM SHBM klla-90-AK klla-90-AK klla-90-AK klla-90-AK MV MV MV MV

27.5t/h 27.5t/h 27.5t/h 27.5t/h 41.6 t/h 41.6 t/h 41.6 t/h 41.6 t/h 39.48m3/s 39.48m3/s 39.48m3/s 39.48m3/s

1999

Middle Normal Normal Middle Middle Middle Middle Middle Middle

24

Electrical. All the steam turbine generators (STG) are of capacity 100-125 MVA at 10.5 kV, which is stepped-up to 220 kV from Units #1-4 and to 110 kV from Units #5-6. There is a 125 MVA autotransformer interconnecting 220 kV and 110 kV lines. The 110 kV line is also connected to TES #3. All protection relays are of original Russian design. The SCADA unit (Honeywell) was installed in 1999. There is no remote control of circuit breakers from the NDC (National Dispatch Centre) control room. As for the 110 kV circuit breakers (CB), one SF6 CB (GE Alsthom make) was already installed in 1998 with USAID financial support and the remaining 14 CBs were replaced with Siemens CBs during 2003-2004. As for the 220 kV CBs (13), one was replaced with GE Alsthom and two SF6 CB (XI'AN HV Apparatus make) were already installed in 2002. All remaining 220 kV oil-filled circuit breakers are of old Russian designs, which will be replaced with SF6 CBs (with SIDA aid) in the near term. Table 1.3.9 - Present Status of Electrical Equipment
Existing conditions with rehabilitation needs The bushing of No.6 main transformer has been damaged and requires repair or replacement. Regular maintenance is required. Oil leakage prevention measures needed. No specific troubles. Renovation is not required. No specific troubles. Renovation is not required. No specific troubles. Renovation is not required. No specific troubles. Renovation is not required. Deterioration of insulation. Regular maintenance is required.

Main Transformer Circuit Breaker Disconnecting Switch Condenser Reactor Metal Clad Switch Gear Cable

Controls and Instrumentation. Boiler system controls are a vital part of the overall control and instrumentation of the power station and are composed of 17 automatic control loops per boiler. The drum water level and steam temperature control loops are operated in automatic control and the other 15 loops by remote manual operation. In phase I of the Japanese soft loan project, the controls and instrumentation of the boiler units #1 -#4 were refurbished and, presently, the controls and instrumentation of the remaining 4 boilers (#5-#8) are under rehabilitation within phase II of the Project. Before the Japanese loan project, the controls of boilers were of analogue control type from Teplovi Automatic of Moscow. Water supply and treatment systems. There are 12 pumps for ground water collection connected with 4 pumps for delivering a total capacity of 1,260 tons water per hour to the Power Station. The ground water collection is situated about 22 kilometres from the Power Station. Typically, about 730-760t/h of water delivered to the Power Station is treated by the water treatment system (about 500 t/h are used for make-up of district heating system and about 200 t/h and above is used to make-up of the condensate loss and boiler loss makeup). Water, utilized for cooling the equipment, is used for the ash handling system. The water purification system is a separate operating system and with 2 step sodiumcationic filters.

25

Characteristics of Cooling System

Description Unit Design Max Operational

Water cooling system

Year of commissioning Number Capacity Type Present operational level Temperature input Temperature output Efficiency Year of last major overhaul 1983 3 22500m3/h

oC oC

32 20

Main cooling water pump

Number Maker Type Suction pressure Speed Consumption Type of control Motor rating 6 Russ Livgidromash -12500-24 1 493 1000 Remote 950

ata rev/min kW kW

1 493 1000 950

1 493 1000 950

Characteristics of Feed Water System

Description Unit TG-1 TG-5 TG-6

Low Pressure Heater

Maker Type Year of commissioning Number Year of last major overhaul Russia PN-130-16-10: PN-200-16-7 1983 1991 4 4 2000 1998 Ata C m3/h Ata
0 0 0

1992 4 1999 10 160 28 10 40 145

Steam
Pressure Temperature Flow 10 160 28 16 40 150 10 160 28 16 40 160

Water
Pressure Temperature inlet Temperature outlet C C

Deaerator
Maker Type Year of commissioning Number Year of last major overhaul

Steam
Pressure Temperature Flow Ata C m3/h
0

26

Water
Pressure Temperature Inlet Temperature Outlet Ata
0 0

C C Russia PV-425-230 1983 1991 3 3 1991 1999

High Pressure Heater

Maker Type Year of commissioning Number Year of last major overhaul

1992 3 1999 13/26/45 265/345/420 10.5/32/26 230 158 230

Steam
Pressure Temperature Flow Ata C m3/h Ata
0 0 0

23/35/50 420 32 230 160 230

23/35/50 420 32 230 160 230

Water
Pressure Temperature inlet Temperature outlet C C

Description

Characteristics of Feed Water System Unit TG2 TG3 Russia PN-250-16-7 1985 1987 4 4 2000 1998 ata C m3/h ata
0 0 0

TG4

Low Pressure Heater

Maker Type Year of commissioning Number Year of last major overhaul

4 1998 7 0.204/0.8/2.78 190 17 16 40 160 130 22,2 10 40 145

Steam side
Pressure Temperature Flow 7 190 17 16 40 150 Barnual Boiler Zavod DB-65-1-3 1985 1987 8 1996 1999 ata C m3/h ata
0 0 0

Water side
Pressure Temperature inlet Temperature outlet C C

Deaerator
Maker Type Year of commissioning Number Year of last major overhaul

1992 2000 9 172 6 170

Steam side
Pressure Temperature Flow 7,8 172

Water side
Pressure Temperature Inlet Temperature Outlet 7,8 70 160 9 70 160 6 70 158 C C

27

High Pressure Heater

Maker Type Year of commissioning Number Year of last major overhaul Russia -425-230 1985 3 2000 ata C m3/h Ata
0 0 0

1987 3 1998 13/23/35 400 20 230 160 230

1992 3 2000 11.3/21.8/33.6 400 263/338/337 20 18.6/16.9/27.6 230 160 230 230 158 230

Steam side
Pressure Temperature Flow 13/23/35

Water side
Pressure Temperature inlet Temperature outlet C C

Description Maker Type Year of commissioning Year of last major overhaul

Characteristics of Condenser Unit TG-1 TG-5 Russ Russ 80KTSS-1 80KTSS-1 1983 1991 2000 year 1998 t/h kgs/cm2
0

TG6 Russ 80KTSS-1 1992 1999 220 0,08 40

Steam
Flow Pressure Temperature 180 0,068 40 8000 2,4 20 0,8 Steel 227 0,094 60 8000 2,4 20 1

Water
Flow Pressure Temperature Pressure loss t/h kgs/cm2 C kgs/cm2
0

2 20 1

Material
Shell Tube

Description Maker Type Year of commissioning Year of last major overhaul

Characteristics of Condenser Unit TG-2 TG-3 Russ Russ KG-2-6200-1 1985 1987 2000 1997 t/h kgs/cm2
0

TG4 Russ

1998 210 0,08 40 10000 2 20

Steam
Flow Pressure Temperature 0,057 40 16000 2,4 20 325 0,094 60 16000 2,4 20

Water
Flow Pressure Temperature t/h kgs/cm2
0

28

Pressure loss

kgs/cm2 Steel Copper

0,8

Material
Shell Tube

Equipment
Pump Valves Piping

Equipment for District Heating Existing conditions with recent made rehabilitation.
The variable speed drives were fitted to motors by the aid project of ADB. Valves are in normal condition and renovation is not required. Pipes are in normal condition and renovation is not required.

Coal Supply. At present, TES #4 uses Baganuur and Shivee-Ovoo coal as the main fuel. These two types of coal have the following characteristics. The maximum calorific value (mean) was 3,617.8 kcal/kg, while the minimum was 3,091 kcal/kg. The maximum ash content was 21.5 %, while the minimum was 10.4 %. The maximum water content was 33.3 %, while the minimum was 26.7 %. All these items have very large variation. This causes a problem for maintaining stable combustion with the existing burners with coal calorific values below 3,000 kcal/kg with high moisture content of 30 % level. The design calorific value of coal for the boilers is 3,500 kcal/kg. To maintain stable combustion with such coal on light load, it is necessary to add firing of high-priced heavy oil. The burning of coal with heavy oil is not only extremely unfavourable from an economic viewpoint but also detrimental to the environment, because burning both fuels at once requires stopping the operation of the electrostatic precipitators. The Baganuur coals have relatively high calorific value and have a favorable combustion performance. The boilers are designated to the Baganuur coal (3500kcal/kg) and the blending it with Shivee-Ovoo coal will compel the boilers to operate at below 3500 kcal/kg, while coal blending is of several options available for reducing emissions and (improve efficiency) from coal fired power plants. The particular problems associated with the Shivee-Ovoo coal mine include the following points (i) the coal is also known as "black brown coal" and has extremely low calorific value; (ii) as there are no cleaning facilities at the mine large rock and coal lumps are not removed; the coal also includes some iron; and (iii) the large rock and coal lumps from the hopper drop on to the conveyor belt causing damage to the conveyor. Meanwhile, the old indirect firing system was rehabilitated with direct firing system as a result of the Japanese Loan Project (see the following table). Coal unloading system. Coal unloading system is comprised of BPC-125 type 2 dumpers that can each dump a coal wagon of 125 tons every 5 minutes,
Coal Supply System Related Items Existing conditions with recently completed rehabilitation. Replaced by the Japanese loan project. They are not necessary after the Japanese loan project. They were replaced with the new firing system. They were replaced with the new firing system

Mill Cyclone Coal dust Coal Feeder

29

Figure 1.3.4 - Coal Handling System

30

Description Mill
Maker Number Type of mill Rotation Capacity of motor Capacity of mill Average Consumption Capacity of bunker

Characteristics of Air and Dust System Unit Design Max

Russ piece rev/min kW t/h kW t 8 SHBM370/675 17,2 32 41.7t/h 1600 400m3 Russ kW rev/min kW/h 150*103 m3/h 8 660 1480

Operational

Exhaust fan
Maker Number Capacity of motor Rotation Consumption Capacity

Forced draft fan

Capacity of motor Rotation Consumption Capacity kW rev/min kW/h

VDN32B
1250/750 750/600 480*103m3/h

Induced draft fan

Capacity of motor Rotation Consumption Capacity kW rev/min kW/h

DOD31.5
1700 495 934*103m3/h

Ash removal system. The ash removal system: drying, reuse of water, and ash pond are located 3 km away from the plant. Ash Treatment System Existing conditions with recently completed rehabilitation
Pumps are in good condition. Valves are in normal condition and renovation is not required. Pipes are in normal condition and renovation is not required.

Equipment
Pump Valves Piping

1.4

Upgrades/Renovations

1.4.1 Implemented Projects Due to a shortage of funds, spare parts and material shortages, and the irresponsibility of personnel, the plant's operation was unstable from 1991 to 1993. Numerous accidents and delays occurred; the volume of generation and financial income decreased. From 1993, foreign investment, loans and grants increased and thanks to proper allocation of domestic capital and improvement of labour discipline, initiative and active work, there were improvements in plant operation and extensive technological renovations began. As a result, the accidents and delays decreased and economic indices improved and the plant's performance stabilized, and the generation has been increasing year by year. Initially

31

100% Russian made equipment was installed at the plant. As part of the technical and technological renovation, some modern equipment has been installed from Asian and European countries. The following are a summary of the renovation projects: (i) The most eroded parts of all 8 steam generators' heating tubes are being replaced; the pulverized coal handling system was transferred to a fundamentally different system including a pulverized coal handling system with vertical ball mill, cyclone, separator, pulverized coal bunker, pulverized coal feeders and very long ducts to transfer the coal to its direct firing (Japan, Germany); (ii) Control systems of the boilers were completely replaced with a new computer SCS automatic control system for boilers #1,2,3,4 and DCS control system for boilers #5,6,7,8 (Japan); (iii) The excitation system of electric generators #1,2,3,4 were replaced with a computerized electronic system (England) (iv) Boiler feed water pumps (#1 and #2) were replaced with pumps with variable flow, computer, full automatic control system (Germany, Denmark, China); (v) Control and monitoring system of 8 feed water pumps was changed to computer control to ensure reliability (TES4); (vi) Introduced a new computerized automatic control system to transport coal to the boiler coal bunker in the station premises (Czech Republic); (vii) Replaced all calculating, technological measuring and monitoring devices with advanced, more accurate, reliable ones and renewed the laboratory and testing stands for their calibration and adjustment (TES4); (viii) Partially replaced the plant's walls, ceilings and metal structures; (ix) Replacement of 70 percent of around 300 initially installed 6kV, 110kV and 220kB oil circuit breakers with Russian, German, Japanese, and Chinese vacuum and insulating gas circuit breakers to improve their reliability (under projects and TES4); (x) Introduction of AYPA abnormal performance control and registering automatic system for all industrial electric equipment (Russia and TES4); and (xi) Avoidance of annual shutdown maintenance as a result of development of main schemes of the plant's technological operation (TES4). Improvements in plant's operation and increase in economic efficiency as a result of above-mentioned projects and major technical and organizational activities have resulted in; (i) increase in production, (ii) decrease in internal service electricity consumption and (iii) decrease in fuel consumption per unit electricity generation. 1.4.2 Details on Japanese Loan Projects Phase I: Boilers #1, #2, #3, and #4. The rehabilitation work on the 4 boilers (No.l to No.4) included dismantling and reconstruction of the relevant equipment. The scope of rehabilitation for the boilers was as follows: 1. Installation of a direct firing system with 4 sets of bowl type vertical mills together with their pulverized coal bunkers replacing the existing 2 sets of tube type mills. The new mill system consists of 4 sets of coal feeders, 4 sets of bowl mills, 4 sets of primary gas fans, 4 sets of seal air fans, 4 sets of lubrication systems, 400V and 6 kV switch gear and 12 sets of pulverized coal piping and hot gas ducts. 2. Replacement of existing control and protection systems for boiler and mill systems, including control panels, control desk, control drive, measuring devices and

32

automatic protection systems. Feed water, spray and blow down control valves were also installed. Control and power cables for all measuring devices, controllers and actuators were completely replaced. Existing control and measuring devices and contactors for each boiler were replaced with the computerized automatic control system. 3. 70 % of furnace tubes were replaced with new ones. 4. The renewal of the control instrumentation for steam and water quality, secondary air damper and associated insulation. Phase I: Control and instrumentation. Controlling the fuel supply manually cannot regulate pressure fluctuation of main steam flow due to load changes, therefore the pressure control valves are used and a huge amount of the boiler fuel is lost. Also the forced draft fan (FDF) vanes are used to reduce airflow resulting in lower efficiency of the boilers. The operating conditions of the boilers before being rehabilitated were as follows (at normal operation of 375 t/h steam production with load change of 56t/h): Drum pressure (Main steam pressure) Main steam temperature Drum level 134 kgf/cm2 20.3kgf/cm2 525C16C NWL 20mmAq

After rehabilitation, the boilers will be able to operate in fully automatic condition as follows (at normal operation of 365 t/h steam production with load range of 32t/h): Main steam pressure Main steam temperature Drum level Furnace pressure Flue gas O2 1302.2 kgf/cm2 5558.8 C NWL4mmAq Set point (-3mm)3mmAq. Set point (6%)+0.5%

It is obvious that the rehabilitated boilers can be controlled within small values of fluctuation and huge amount of fuel savings are expected. The automatic operation of the boilers will also reduce the amount of work by the operator and will reduce mistakes (human error). Expected Overall Effect including Phase I and Phase II. Project Life and Increase in Output. The Project Life is estimated at 24 years with operation of 20 years from the year of 2003 and will increase in power and heat outputs throughout the project life. The incremental outputs are calculated based on the data issued by the Energy Authority. Operational indicators of the Project at the level of 2007 are (i) net electric energy production will increase by 15% against net production of 2000 (1542 GWh); (ii) maximum electric power demand will reach 410 MW (330 MW was the level in 2000); and (iii) utilization factor will amount to 46% when it was 40,4% in 2000 year level. The data shows a projection of respective power and heat outputs of the 4th Thermal Power Station until the year of 2006. It is assumed that the full output reached in 2003 will be kept constant until the end of the project life. The annual power output without the Project is also technically estimated on a condition that the present facility will be properly maintained. It is also assumed that the capacity of turbines and generators will be adequate to meet the estimated increase of the power and heat output.

33

Increase in Operation and Maintenance Cost. The new facilities introduced under the Project will lead to additional operation and maintenance (O&M) costs. The cost increase will be charged from the year of 2003 and increase with time. The initial incremental cost is estimated at 1,193,500 thousand Tug.in 2003 and will be kept constant at 1,912,000 thousand tug rug, through the year of 2011. It is also assumed that the incremental cost of 2,387,000 thousand Tug. will start in 2012 and continue throughout the project life. Increase in efficiency of boilers and reduction of auxiliary electrical power. The new power system is expected to result in an efficiency increase of the boilers and also a reduction of auxiliary electrical power. Both factors can be converted into reduced coal consumption. The estimated amount of reduction coal consumption is 180,830ton/year and 50,400 ton/year respectively. If only 70% of volume of coal reduction is achieved and applying the current average coal price at 6,400Tug. /ton, the calculated savings are 810,112 thousand Tug. /year and 228,352 thousand Tug. /year. Effect on Environmental Conditions. About 3500 thousand tons and 2000 thousand tons of coal have been consumed in Ulaanbaatar city and by the 4th Thermal Power Station a year respectively (the relevant CO2 emissions are 2791 thousand tons and 1595 thousand tons per year). As a result of the Japanese loan project, the coal consumption of the TES#4 will be reduced by 231,230 tons a year (184000 tons of CO2 emissions). These remarkable reductions of emitted CO2 will contribute to the reduction of global warming, as well as the health protection of people living in Ulaanbaatar city. 1.5 Environmental Protection

Environmental Status. Mongolia is a large and sparsely populated country with a harsh climate and about two and half million people inhabitants within an area of 1.57 million square kilometres. The climate of Mongolia is dry and has extremely cold temperatures in winter. Annual average precipitation in Ulaanbaatar (capital city of Mongolia) is only 293mm. In the southern areas surrounded by the semiarid steppes and Gobi desert and in the eastern area also surrounded by the semiarid steppes, 70 to 80 percent of total precipitation is concentrated in three months (from late June to mid September). The country is situated at high northern latitude and at a high elevation (average 1,580 meters). The average annual temperature is very low (in Ulaanbaatar, the average annual temperature is - 0.6C). As the country is also isolated from the sea, the temperature during the year fluctuates widely (- 39C to +38C in Ulaanbaatar). The winter is long, cold and dry with low wind and frequent temperature inversions. These climate conditions have a direct influence on environmental conditions in Mongolia. The climate in Ulaanbaatar city is shown on Table 1.5.1. Table 1.5.1 Temperature, Precipitation and Humidity in Ulaanbaatar City Parameter 1 2 3 4 1.5 5.8 52 5 9.8 6 7 8 9 10 1.1 11 12 Ave

Temp (C) -20.9 -17.1 -8.0 Precipitatio 2.4 n (mm) Humidity 81 (%) 2.4 77 6.6 66

14.3 16.7 15.1 8.8

-11.6 -17.3 -0.6 5.4 72 4.8 81 *293 67

14.6 55.6 64.0 92.7 26.9 12 52 58 65 70 65 64

(Data: 1986~ 990) Meteorological research 1991.7 * - shows total precipitation in a year.

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As Ulaanbaatar city (capital city of Mongolia) is located in a basin surrounded by mountains of height of 1652 to 1949 meters above sea level, the air pollution induced by the temperature inversion is greater than other cities of similar nature in the world. The temperature inversions occur during the months of October to April. The temperature inversion occurs at the level of 650-920 meters above ground level. Sand storms intermittently occur (about 26 times a year). Air pollution also results from the uncontrolled emissions from industries using coal, from heating only boiler stations, and emissions from households burning coal for room heating. The wind roses in Ulaanbaatar show the wind direction from west to North West and the wind velocity is 1 to 2 meters per second. The smoke and flue gas in Ulaanbaatar city have been mainly emitted from stacks of coal-fired thermal power station and Mongolian traditional houses (called "gher"). Forty-eight (48) percent of the population of Ulaanbaatar city live in "gher" using stoves fuelled with coal/and/or wood both for house-warming and cooking purposes. From these fuel sources toxic substances such as carbon monoxide are emitted into the atmosphere. Environmental Pollution. In Ulaanbaatar city, there are four air-quality monitoring stations by which the daily concentration of NO2, SO2, CO and dust are measured under the Japanese loan project. From these measurements it is noted that the emission of NO2 and dust often exceed the permissible level. TES#4 has a stack with a height of 250 m, inner diameter-8 m, and base diameter35m. There is an electro-static precipitator (ESP) of EGA2-58-12-6-4 type, which is installed for removal of fly ash in flue gas and has an efficiency of ash removal of 98-99%, voltage for electrode 40-5-50 kV and allowable flue gas temperature of 150C. The ESP is switched on and off by remote control with an automatic control system as part of the rehabilitation activities under the Japanese Grant Aid. Before this rehabilitation the ESP experienced problems with the ash disposal system and problems with the motor-gear for the vibration system. Sometimes the capability of ash removal was reduced by 25-30% and was stopped for over 2200 hours for maintenance. Since 1992, maintenance hours have reduced down to 1200 hours and the effectiveness has increased to 98% as a result of this grant aid rehabilitation project. Operating effectiveness of the electrostatic precipitator (ESP can be evaluated using the air quality monitoring station data for, NO2, SO2 and O2 emission levels (Tables 1.5.21.5.4). Table 1.5.2 - Method of Analysis

Item
SO2 NOx O2

Method
Controlled potential electrolysis method Model NOS-700, (Best instrument Co., Ltd) Controlled potential electrolysis method Model NOS-700, (Best instrument Co., Ltd) Zirconia type oxygen method Model NOS-700, (Best instrument Co., Ltd)

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Table 1.5.3 - Dust Data (Annual) Date

EP inlet EP outlet g/m3N) efficiency (%) C02 % O2 % N2/o H20/o
Recorded by:

1993
7.51 0.66 91 12.6 6.3 81.1 8.3
Power Station

1994
13.83 0.33 98 13.8 5.0 81.2 8.4

1995
13.71 0.45 97 14.6 4.3 81.1 6.4

1996
0.965 0.004 100 11.5 5.4 83.1 7.7

1997
7.71 1.08 86 14.5 5.1 80.4 -

1998
13.26: 0.54 96 13.2 6.6 80.2 4.5

Table 1.5.4 - SO2, NO2, and O2 Data Point: EP outlet Unit date NOx (ppm) S02 (ppm) O2 (%) Point: EP inlet Unit date NOx (ppm) SO2 (ppm) O2 (%) Point: EP outlet
Unit date NOx (ppm) SO2 (ppm) O2 (%) #3 1998/10/26 141 148 120 474 440 398 5.5 5.6 8.7 #5 110 374 9.3 252 330 11.7 247 324 11.8 242 317 12.0 #6 225 236 13.4 208 216 13.8

#1 #2 1998/2/24 190 296 247 480 15.0 11.2

#6 #3 1998/10/8 274 178 540 467 8.8 9.6

#5 320 599 11.4

#3 1998/10/26 60 375 11.8

101 507 8.2

92 496 6.6

78 482 8.5

Recorded by: Power Station

All the wastewater from the power station is collected at the Slurry pit. The wastewater is pumped to the ash disposal pond, in the amount of about 2000t/h. This pond is situated about 4 km away from the power station and has a circumference is about 2 km. The ash is settled and the superficial water is sent back from the ash disposal pond to the power station for recycling without being discharged outside. This system has no treatment equipment. Figure 1.5.1 shows the wastewater flow.

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Figure 1.5.1 - Ash Disposal Flow Diagram with Water Noise from the power station is a very low level at the area surrounding the power station However, sometimes a high sound level is created when the electric valves release steam resulting from bringing a boiler into parallel with the other boilers. This sound level is 88dB (A) at about 60m from valves. Figure 1.5.2 and Table 1.5.5 show measurements of sound level at power station and Figure 1.5.3 and Table 1.5.6 shows measurements of the sound level outside the power station.

Figure 1.5.2 - Measuring Sound Level at Power Station

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Table 1.5.5 - Sound Level Measurement (Inside of Power Station)

Point
Bldg side Cooling tower Turbine side ditto ditto ditto ditto ditto Cooling tower Stack side ditto

Sound level
57

Point
Stack side ditto ditto ditto ditto ditto

Sound level
70 71 66 64 62 61

Point
1 #3 IDF 2 #3 IDF 3 #3 IDF 4 #3 IDF 5 #3 FDF 6 #3 FDF 7 #3 FDF 8 #3 FDF 9 #3 Mill 10 #3 Mill 11 #3 Mill

Sound level
86 91 88 86 84 91 94 92 90 102 100

84 66 73 76 71 63 66 77 66 69

Figure 1.5.3 Sound Level Measurement Points (Outside of Power Station)

Table 1.5.6 - Sound Level Measurement (Outside of Power Station) Point Road Gate 2 km from Gate Road Road Gate Road Sound level 46 51 45 48 44 45 46 Place Resort Resident Clinic Hotel

Table 1.5.7 - Noise Standard

Time 23:00-7:00 7:00-23:00 23:00-7:00 7:00-23:00 23:00-7:00 7:00-23:00

dB(A) 45 35 55 45 55 60 50

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Table 1.5.8 - Present Status of Environmental Equipment

Equipment
Electric Precipitator Water Treatment System Waste Water Treatment System Measurement Instruments

Existing conditions with recent rehabilitation.

Wear and tear of electrode, damage of hammering equipment. It is necessary to check the function of EP by instrument. Replacement is not required. No specific trouble. Required regular inspection and maintenance. Replacement is not required. It is observed that there is contamination of ground water in the ash disposal ponds. In the long term there is a need for improvements of the wastewater treatment. Dust, SO2, NOx, noise and water quality measurements are taken using a portable instrument from the plant laboratory.

2.0 Energy Efficiency Improvement Options As discussed in Chapter 1, considerable improvements in the continuous and reliable operation of the TES#4 were achieved in 1995-1999. The ongoing Phase II of the Japanese loan project is designated to maintain and increase the results of its Phase I. Generally, the efficiency improvements in the power plants pursue a triple target (i) reduction of the specific fuel consumption and thus of the generation costs; (ii) contribution to the indirect emission reduction; and (iii) preservation of coal resources, not only as a precautionary measure, but also having in mind the economic consequence that natural resources will become scarce and more expensive due to the consumption in the long run. For meeting the economic goals it is necessary to reduce the investment costs and increase the efficiency of power plants at the same time. In this connection, the energy efficiency options for the power plants are more promising than the technological changes. Table 2.1 summarizes some of the potential actions that are commonly taken to improve plant efficiencies in western countries [Review of Potential Efficiency Improvements at Coal-Fired Power Plants7]. This data are based on the higher moisture "brown coal" or lignite similar to Mongolian coals. These actions include those that would help restore the plant to its design conditions, change existing operational settings, or install retrofit improvements. In power plant operations, two main goals are set forth from an integrated environmental and engineering perspective: to burn the fuel cleanly and to exploit as much as possible of the fuels energy value. With regard to energy exploitation, there are inherent inefficiencies in the production of electric power. Efficiency in coal fired power generation is measured by the portion of the energy in the fuel that is converted into electricity and heat at the power plant for delivery to the customer. Factors involved in overall efficiency include: combustion, thermal transfer, and generator, transmission, and end-use (consumer) efficiencies.

7 The Clean Air Markets Division, U.S. Environmental Protection Agency contracted Perrin Quarles Associates, Inc., to perform a review of readily available data on potential and actual efficiency improvements at coal-fired utilities.

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Table 2.1 - Measures that may improve the Efficiency of Coal-Fired Power Plants
ACTION8 EFFICIENCY IMPROVEMENTS (%) 0,42 0,46-1,97 0,84 1,1 0,84 1,22 0,84 2,1 0,98 1,97 0,84 1,97 0,32

Restore Plant to Design Conditions

Minimize boiler tramp air Reinstate any feed-heaters out of service Refurbish feed-heaters Reduce steam leaks Reduce turbine gland leakage

Change to Operational Settings

Lower excess air operation Improved combustion control

Retrofit Improvements
Extra air-heater surface area in the boiler Install new high efficiency turbine blades Install VSD on motors Install on-line condenser cleaning system Install new cooling tower film pack Install intermittent energization to ESPs

The measure of coal drying with heat recovery is a capital-intensive process and the technology has not been used on a major utility boiler. Hence it should be viewed as being not commercially nor technically proven at this stage. Because of the different plant configurations and the variable conditions of the each station, not every item can be implemented at each station. There are a number of items, which will 'overlap' in their effect such that the efficiency gains are not directly additive. For example extra air-heater surface areas, lower excess air, minimisation of tramp air and re-installation of feed heaters will interact such that the overall improvement will be significantly less than the sum of the individual items. For each station detailed calculations would need to be undertaken to determine the combined effect of inter-dependant initiatives. For a number of the initiatives the gain in efficiency stated would appear to be optimistic. The improvement of 1.97% stated for the installation of variable speed drives needs to be considered in relation to the overall auxiliary power usage, approximately 8%, and the extent of variable speed drives already installed. The motors without variable speed drives amount to less than 4% of generated output and thus a saving of approximately 50%. These savings levels would thus seem to be unattainable at TES#4. Variable speed drives usually show an efficiency improvement only where the station operates for a proportion of time at lower loads. Because of the economics, brown coal fired stations do not normally operate for long periods at low loads. Another efficiency improvement measure where the nominated gain would appear to be optimistic is for the improvement of the cooling tower performance by the inclusion of a film pack. A potential improvement of 1.97% has been stated. Based on a theoretical thermodynamic calculation in order to achieve this improvement a reduction in condenser pressure of 3.5 kPa would be required which in turn would necessitate an 8oC reduction in
8

They are options such as various equipment control upgrades such as distributed control systems, precipitators and turbine controls; metering upgrades; boiler chemical cleaning upgrading; feed water heater improvements; reduced condenser air in-leakage and reduced thermal losses.

40

cooling water temperature. A film pack is capable of reducing the water temperature by only some 3oC. The foregoing analysis is based on theoretical considerations. In practice, because of the restriction of the exhaust flow area, the actual gain in efficiency due to an improvement in condenser pressure will be below the theoretical predictions. Using the assumptions for gross electricity and heat generation levels, the total fuel heat rate, gross electrical efficiency and station efficiency of the TES#4 are 2150 GWh, 3040 GWh, 8592 GWh, 25,2% and 60.4%, respectively, at the present level, the avoided CO2 emission costs for the more viable options have been estimated (see Table 2.1B). Table 2.1B Avoided CO2 Emissions from Energy Efficiency Options (UB TES#4 case)
Reduction of Fuel heat rate GWh/yr CO2 emission reduction 103tons/yr 123,18 272,19 53,54 62,39 131,7 CO2 emission reduction cost 103 US$/yr 615.9 1360,9 267,74 311,95 658,54
41

Action

1 2 3 4 5

Cooling tower film pack Coal drying with heat recovery On-line condenser cleaning system High efficiency turbine blades Extra air heater surface in the boiler + add. soot blowers

62,36 64,9 61,24 61,38 62,5

269,34 595,06 117,13 136,46 287,98

In order to advance the practical options for efficiency improvement a soundly based engineering study with costs would need to be undertaken for TES#4 With regard to clean coal burning, the traditional focus has been on particulate, SO2, and NOx emissions. Table 2-2 provides a layout of clean coal technologies that might fall under the pollution prevention umbrella, depending on either the parallel implementation possibilities of options or overall impact of a particular option. Options under the retrofit category may be applied to existing power plants, whereas options under the new/repowering category would generally apply to new or substantially modified facilities. Table 2-2 Selected Clean Coal Technologies Pre-combustion
Physical Cleaning Fine Grinding Advanced Froth Flotation Heavy Media Cyclones Micro bubble Flotation Advanced Drying Physiochemical Molten Caustic Leaching Microbial Bioleaching

Combustion
Low NOx Burning Multistage Burning

Retrofit
Gas burning Re-

Avoided Coal Consumption 103tons/yr 76.99 170,12 33,47 38,99 82,32

Increased efficiency %

New/Repowered
Fuel Changes Fluidized-Bed Combustion10

Fluidized-Bed Combustion

10

The most efficient heat transfer method for counter-flow cooling towers is accomplished via cross-corrugated film-type media or fill. This fill is thermally formed from rigid polyvinyl chloride (PVC), which resists decay and fungus or biological attack.

Recent technological developments have led to the capability of powering "combined-cycle" generators. Two new technologies Pressurized Fluid Bed Combustion and Integrated Gasification Combined Cycle (IGCC)

OPTION-1 Coal Cleaning Most naturally occurring low-sulfur coals in Mongolia, including the coal used in TES#4, have distinct handling and combustion characteristics and, therefore, chemical and biological cleaning11 is not required. Low rank coals in Mongolia have relatively high ash and moisture content. Due to their high moisture content, coals of the Baganuur and Shivee-Ovoo have a low heating value. For Mongolia, coal cleaning has not been performed either at the mines or at the power plants up to the Baganuur and Shivee-Ovoo Coal Mine Development Project. Coal cleaning is very important to reduce ash and moisture content in order to increase the coals heating value. Within the above project, implemented during 1997-2003 with the help of JBIC of Japan, the dewatering systems were constructed and environmental monitoring and coal analyses equipment was supplied to the mines of Baganuur and Shivee-Ovoo, from which the TES#4 receives coal. They are in fully normal operation to date. Coal cleaning also provides economic benefits from reduction in shipping costs. Cleaning requirements with regard to size, ash, and moisture content has evolved from consideration of engineering and operating efficiency concerns. Presently, a permit system for sources of pollutants from the power plants is not in force in Mongolia and the power plants are buying the relevant coal from the certain mines with designated coal, without considering moisture and ash content. If there was implementation of coal cleaning technology in the Baganuur and ShiveeOvoo coal mines, from which the TES#4 takes its coal, or in the premises of the TES#4, the calorific values would increase and the ash contents would decrease substantially, and the station overall efficiency would increase by 2-5 % depending on the applied technology. On average, if coal cleaning technology was applied in the TES#4 it would reduce coal consumption by 134.4 thousand tons of coal per year, which would equal to a CO2 emission reduction value of 1.07 million US$ if CDM credits were possible with this change. OPTION 2 Low NOx Burners Controlling NOx by new or retrofitted low NOx burners is a viable energy efficiency and pollution prevention option. One common approach is to control the mixing and characteristics of fuel and air in the region of the furnace near the burner to slow the conversion of fuel-bound nitrogen to NOx, while still maintaining high efficiency in combustion. This task is realized by controlling the quantity, momentum, and direction of the fuel and air streams at the throat of the burner as they are introduced into the chamber of the furnace. The formation of nitrogen oxide increases at higher temperatures and with the level of surplus oxygen present during combustion. As a result, if the available oxygen level in the critical NOx formation zone is limited, and the amount of fuel that is burned at peak temperatures is reduced, NOx emissions decrease. From the judgments in the foreign

have enabled combined cycle operations in the context of coal-fired facilities. These facilities have dramatically improved efficiencies or heat rates as compared to conventional pulverized coal-fired facilities. [Review of Potential Efficiency Improvements at Coal-Fired Power Plants, DOE, USA]
11

Coal may be cleaned, generally, by physical and chemical/biological means.

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literature, the low- NOx burners are being considered as a reasonably available control technology (RACT) for electric steam generating units. OPTION 3 - Repowering with CFB Boilers. The challenges that the Mongolian energy industry face can be summarized as follows: (i) Improve efficiency of coal utilization and utilise available resources of coal wastes to reduce the deficit of coal production and improve the economics of coal power plants. (ii) Improve reliability and maintainability of existing generating units by replacing the most worn-out coal fired boilers and extending the useful life of other boilers until they can be replaced by modern equipment. (iii) Reduce air pollution from coal-fired power plants by adhering to stringent emissions limits for the replacement coal-fired boilers and improving the environmental performance of rehabilitated units. One of the most important tasks regarding the increase in efficiency and reliability of the most important power plant in Mongolia is the repowering of the aging TES#4 for improved utilization of low-grade indigenous coals. No new power stations are planned until the year 2010. It is expected that TES#4 will run after 2020 and it must continue to play a vital role in supplying ample and stable electricity to meet the domestic as well as industrial power demand. Therefore, there is a repowering option, which uses a number of new plant components and integrates and utilizes the existing components to the maximum extent practical. The CFB boiler technology provides the answer to the problems of upgrading the TES#4 for the following reasons: CFB boilers have a proven ability to efficiently utilize low-grade fuels, including those with high ash (up to 60%) contents, without the use of supplemental fuel within a wide load range. There is a potential for utilization of sludge and other coal wastes in CFB boilers by adding them to the main fuel. A technology of sludge preparation can be developed for fluidized bed combustion, which includes drying and pelletizing. CFB boilers provide SOx and NOx emission control meeting stringent pollution limits without the use of back-end gas scrubbing equipment. This has a special importance for Mongolia, which does not make this equipment. It is necessary to evaluate the economic effectiveness of rehabilitated boilers completed under the Japanese project with reliable and efficient continuous operation. In the long-term, these rehabilitated boilers should be replaced with a modern clean coal technology like CFB. While the CFB technology will be a long-term solution for upgrading of Mongolian power plants, PC-fired boilers will continue to produce most of coal-based power for years to come. Therefore, their life extension and economically justifiable improvements in combustion efficiency and emissions performance remain an important direction of the power plant upgrading effort. One more advantage of CFB technology is the possibility of increasing coal cleaning for its use as a fuel for PC boilers while adding the cleaning wastes to a fuel for CFB boilers. This would result in better overall utilization of coal for power generation.

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Fluidized-bed combustion12 (FBC) technology involves the combustion of coal suspended in a stream of inert particles and upward-moving air. FBC enhances the burning process so that the combustion temperature can be maintained at levels less favorable to NOx formation (760 to 870oC, about half the temperature of conventional combustion). In addition, FBCs operate at temperatures considerably below the initial ash fusion range (1,150 to 1,550oC) for many coals. This substantially reduces the volume of fireside cleaning wastes and cleaning frequency. Therefore, CFB technology can be successfully applied to utilize high-ash low-grade Mongolian anthracite, while minimizing emissions of air pollutants. Repowering with CFB boilers offers a long-term solution for upgrading of TES#4 and reducing their consumption of imported fuel oil. The existing boilers in the TES#4 are of 220-tons/hr capacities and it implement the program of CFB re-powering of 250-tons/hr capacities. We are circulation of low time CFB, which is not sensitive to coal category and not control level and it is easy to operate. These CFBs should be operated at the 50%-100%. is possible to preparing the requires high load range of

The station efficiency using CFB technology is approximately 0.4% better than the existing solution. This program is estimated to give coal savings of 16,0 thousand tons per year (the CO2 emission reduction value could be 127 thousand US$ if CDM was applicable). Fuel flexibility will provide a useful safety margin for the future. Wet coal slurry (schlamm) waste combustion can be included for 30% of the basic design. OPTION 4 Steam Turbine Modernization The modernization concept for improving the performance of older steam turbines would result in an increase in efficiency to a level comparable with that of new turbines, while maintaining the main dimensions and steam parameters of the existing turbines. In the power industries in the world, there are at a range of modernization products of old steam turbines from several equipment suppliers including Siemens. The preferred solution is replacement of the components in the flow path including the inner casings with components of more advanced design for TES#4. This would offer the greatest potential for increasing turbine efficiency and output. New blading, modified seals and enlarged cross sections are the major issues. As for new blading, the total number of stages, the thermodynamic load on each stage and the design of each stage itself would be optimized individually for the old turbines of TES#4. As described [August 12, 2002, Siemens steam power plant modernization business is trending upwards], this approach allows exceptionally high turbine efficiencies to be achieved. Hence, steam turbine modernization includes as a minimum replacement of the existing moving and stationary blades with new design blades, which have reduced profile and edge losses, have better surface quality and have an optimized blade heightto-width ratio. The leakage through the radial seals can be reduced by smaller gaps and/or by a new system. For the HP steam turbine the double-strip seals are the most efficient. To
12

This technology is applied in three types of designs: atmospheric FBC, pressurized FBC, and two-stage bubbling bed designs, which technologically fit between the two aforementioned designs. Pressurized FBC shows promise in repowering and in new facility construction. This technology is expected to be commercially available between 2000 and 2005.

44

avoid major damage and immediate shutdown of the turbine in the event that the rotor comes into contact with the casing, the strips are caulked in and can be replaced during the next inspection. This design also allows for smaller gaps and tolerances. The inlet and exhaust sections of older turbines may cause vortices and thus pressure drops. This becomes more apparent when the steam parameters are increased. Hence, widening the flow cross-section and optimizing the contour are an appropriate measure to increase efficiency. Outfitting older steam turbines with modern flow-path technology can boost efficiency to levels comparable to those of new turbines. The flow path offers the greatest potential for increasing the output of older steam turbines. It is often more economical to replace the rotor, inner casing, and moving and stationary blades rather than install an entirely new turbine. It is also worth considering rewinding the generator/stator. According to the estimates, given in the Table 2.1B, the new blading project would give coal savings of 39,0 thousand tons of coal per year, which equals to the CO2 emission reduction of 312,0 thousand US$ if CDM could be applied to this project.

3.0 (i)

Conclusions For Mongolia the most technically and financially viable solution in the near term is the further implementation of energy conservation programs, including energy efficiency improvements in the combined heat and power UB power plants, starting with TES#4 as the largest such plant. From 1995, considerable improvements in the continuous and reliable operation of TES#4 have been reached with help of international agencies and donors.

(ii)

(iii) Coal cleaning technology is important for all the power plants and the heat only boilers in Mongolia. (iv) As TES#4 is the main power plant in Mongolia and its design life will be reached in 2020, the further re-powering with Circulating Fluidized Boilers is important for economy to provide the reliable operation of the TES#4 for the years after 2020 and to minimize the total investments in the power and heat generation sub-sector of Mongolia. This option can be considered from 2010-2015 after the current TES#4 Japanese loan project lifetime extension has been fully utilised. (v) In the near-term, the modernization of the steam turbines is the more viable option in the terms of the present rehabilitation and upgrading projects taking place during 1995-2006.

45

References 1. 2.
Survey Report on the Rehabilitation of Ulaanbaatar Thermal Power Plant 4 (phase II), OECF,

2001<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:office:office" /> Progress reports of the Project of the Rehabilitation of Ulaanbaatar Thermal Power Plant 4 (phase II), 2005-2006 3. 4. Final Report, TA 3299-MON Capacity Building in Energy Planning, 2002; Survey Reports, 1999-2000 ( in the framework of the TA 3299-MON Capacity Building in Energy Planning); 5. 6. Annual reports of the Ulaanbaatar Thermal Power Plant #4, 2004, 2005 Summary of the Activities of the Energy License holders for 2004, Energy Regulatory Agency, <?xml:namespace prefix = st1 ns = "urn:schemas-microsoft-

com:office:smarttags" />Ulaanbaatar, 2005

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